Housing for vehicle electric battery module and method for assembling said module

Abstract

Housing for a vehicle electric battery module and method for assembling said module. Housing (2) for a motor vehicle battery module (1) comprising a base (3) having a plurality of walls, a cover (4) comprising at least one main side (41) configured to be mounted on the base (3) so as to close the housing (2), and a fastening device (5) comprising at least one opening (43) disposed in the main side (41) and at least one deformable tab (33) connected to at least one of the walls, configured to be disposed in the at least one opening (43) and to be deformable. Abstract figure: Figure 4

Description

Title of the invention: Housing for an electric vehicle battery module and method for assembling said module

[0001] The present invention relates to a housing for an electric vehicle battery module. The invention also relates to an electric battery module comprising such a housing and a vehicle comprising such a housing and / or such a module. Finally, the invention relates to a method for assembling a battery module according to the invention.

[0002] In electric or hybrid vehicles, current electric propulsion systems rely on increasingly efficient electric battery devices to compete with internal combustion engines. Typically, these battery devices comprise a plurality of electrochemical cells arranged in one or more modules contained within at least one casing. These cells can be cylindrical, prismatic, or flexible.

[0003] The housing conventionally comprises a base open on one side, in which the electrochemical cells are arranged. Once the electrochemical cells are in place, the housing can be closed by means of a cover positioned on the open side of the base. The cover is then secured to the base by a combination of fastening methods such as screws, studs, clips, or even welding. Such fastening methods have the disadvantage of multiplying the number of parts required to assemble the battery module and, consequently, increasing its manufacturing cost. Furthermore, implementing such fastening methods is time-consuming and tends to complicate the assembly of the battery module.

[0004] The present invention falls within this context and aims to offer an alternative to known battery module housings, allowing for a reduction in the cost of the module and a simplification of its assembly.

[0005] To this end, the invention provides a housing for an automotive battery module comprising a base open on one side having a plurality of walls, including at least one main wall and side walls connected to the main wall, and a cover, including at least one main side panel configured to be mounted on the base so as to close the housing. The housing further comprises at least one fastening device comprising: - at least one opening, located in the main side; - at least one deformable tab, connected to at least one of the side walls, configured to be positioned in at least one opening and to be deformed between an insertion position, in which said tab extends along a first direction, in continuity with at least one side wall and transverse to the side main, and a position for securing the cover relative to the base in which said leg extends transversely to said wall.

[0006] In particular, the base is made of a metallic material, such as sheet steel and / or aluminum. Additionally or alternatively, the cover is optionally made of a plastic material, such as a filled or unfilled polymer, and / or of a metallic material, such as sheet steel and / or aluminum.

[0007] Preferably, at least one leg and at least one of the lateral walls of the base came from material.

[0008] Optionally, the at least one fastening device includes at least one stop member, disposed in the cover and extending at the level of at least one opening, said stop member being configured to form a stop for at least one leg along at least one direction when the latter extends into the locking position.

[0009] Optionally, at least one fastening device includes at least one recess, located at the level of at least one opening, configured to receive at least one tab when it extends into the locking position.

[0010] According to embodiment examples, at least one leg has a dimension, along the first direction when said leg is in the insertion position, greater than or equal to 2 cm and / or at least one leg has a dimension, along a second direction orthogonal to the first direction, greater than or equal to 1 cm, or even 2 cm.

[0011] Optionally, the housing according to the invention comprises a plurality of fastening devices such that the housing comprises a plurality of tabs and openings, each tab being configured to be disposed in one of the openings, the plurality of tabs being distributed into a plurality of sub-assemblies arranged such that: - at least two subsets of legs are connected to two separate, opposing side walls; and / or - at least two subsets of legs are connected to two separate, adjacent side walls; and / or - at least two legs are positioned at the same side wall.

[0012] The invention also relates to a battery module comprising a housing according to the invention, delimiting an internal volume, and at least one electrochemical cell disposed in said volume.

[0013] The invention further relates to an electric or hybrid motor vehicle comprising a housing and / or at least one battery module according to the invention.

[0014] The invention also relates to a method for assembling a battery module according to the invention, comprising: - a positioning step of at least one electrochemical cell on the main wall of the base of the housing; - a step of positioning the lid on the case so as to place at least one electrochemical cell in the internal volume and so as to close the case, at least one tab being placed in the insertion position and extending through at least one opening in the lid; - a step of securing the lid to the base by moving at least one tab from the insertion position to the securing position. In particular, such a movement is achieved by bending at least one tab.

[0015] Other details, features and advantages will become clearer upon reading the detailed description given below, by way of example and not limitation, in relation to the various embodiments illustrated in the following figures:

[0016] Fig. 1 is a schematic representation of an embodiment of a battery module according to the invention.

[0017] Fig. 2 is a representation of a part of the battery module including a fastening device.

[0018] Fig. 3 is a representation of a part of the battery module including a fastening device.

[0019] Fig. 4 is a schematic cross-sectional representation of the battery module.

[0020] Figure 5 is a schematic cross-sectional representation of a module housing. battery.

[0021] Fig. 6 is a schematic representation of an insertion position of a leg of the fastening device.

[0022] Fig. 7 is a schematic representation of a locking position of a leg of the fixing device.

[0023] Figures 1 to 7 illustrate an embodiment of an electric battery module 1, which may also be referred to as a "battery" or "electric battery." Such a battery module 1 is intended for a battery system, or electrical energy storage device, of a motor vehicle, particularly a hybrid or electric vehicle. For example, the battery system comprises at least one battery module 1 according to the invention or a plurality of such modules.

[0024] It is also understood that, in all the figures, the dimensions and spacing between the different components may be exaggerated for clarity. Furthermore, in the description below, the terms "first" and "second" are intended to distinguish the different elements of the invention and not to establish a hierarchy among them.

[0025] Generally, the battery module 1 comprises a housing 2, at least one electrochemical cell 11, disposed in said housing 2, in particular disposed in an internal volume 10 delimited by the housing 2. The following description refers to a specific battery module 1 and its associated housing 2. It is understood, however, that the invention can be extended to a plurality of battery modules 1 or housings 2.

[0026] As is known, at least one electrochemical cell 11 may be of the prismatic, cylindrical, or flexible type, particularly prismatic flexible, also known as the "pouch," "bag," or "pocket" type. "Prismatic" means that the electrochemical cell 11 may have a parallelepiped or substantially parallelepiped shape, particularly rectangular or square parallelepiped, or even cubic. Each electrochemical cell 11 is capable of storing energy in chemical form and releasing it as an electric current. Electrochemical cells may, for example, be of the "lithium-ion" type, also called "Li-ion." The battery module 1 comprises at least one electrochemical cell 11. However, as illustrated, it is understood that the battery module 1 may comprise a plurality of electrochemical cells, the number and dimensions of said cells being in no way limiting.

[0027] The housing 2 includes a base 3, a cover 4, removable and attached relative to the base 3, and at least one device for fixing the cover 4 to the base 3.

[0028] The base 3 comprises a plurality of walls and is open on one side to allow the insertion of at least one electrochemical cell 11. "Open on one side" here means that one of the walls is missing and that the base does not form a closed structure. In particular, the plurality of walls comprises at least one main wall 31 and lateral walls 32, connected to the main wall 31 and extending transversely, or even orthogonally, to it. The missing wall is preferably a wall opposite the main wall 31 or one of the lateral walls 32, adjacent to the main wall 31. For example, but not limited to, the base 3 has a parallelepiped shape in which opposing lateral walls 32 extend parallel to each other.The base 3 thus has a “U” or nearly “U” shaped profile, with the main wall 31 forming a base of the “U” while the opposing lateral walls 32 form its arms.

[0029] For example, the base 3 is made of metallic material, such as steel sheet or aluminum sheet, for example 3000 or 6000 series aluminum sheet.

[0030] The cover 4 includes at least one main side 41 configured to be mounted on the base 3 so as to close the housing 2. The cover 4 is thus configured to be mounted at the open side of the base 3 so as to delimit the internal volume 10 of the housing 2 and to close the base 3. The main side 41 of the cover 4 is thus opposite the main wall 31 along a first direction 100.

[0031] Optionally, the cover 4 also includes a side flank 42 or a plurality of side flanks 42, connected(s) to the main flank 41 and extending transversely, or even orthogonally to it. In this case, the cover 4 comprises a plurality of lateral sides 42. In particular, the cover 4 is dimensioned and shaped so that the lateral sides 42 extend into contact with at least a part of the lateral walls 32 of the base 3 so as to limit, or even block, the movement of the cover 4 relative to the base 3 along at least one direction orthogonal to the first direction 100, for example along a second direction 200 or along a third direction 300, orthogonal to the first and second directions 200. Similar to the base 3, the cover 4 then has a “U” or substantially “U” shaped structure, the main side 41 forming the base of said “U” and the lateral sides 42 forming its arms.

[0032] For example, the cover 4 is made of metallic material, such as sheet steel or aluminum sheet, or of plastic material, such as a filled or unfilled polymer material or a composite, for example polypropylene with glass fiber (PPGF). Preferably, such a material is capable of withstanding a mechanical stress exerted on at least a part of the fastening device 5, as further described below.

[0033] The fastening device 5 comprises at least one opening 43, disposed in the main side 41, and at least one deformable tab 33, connected to at least one of the side walls 32. The at least one tab 33 is disposed at a free edge of the side wall 32 bearing it, i.e., at the open side. The opening 43 is through and extends into a thickness of the main side 41 of the cover 4, between a first face 411 of the main side 41, configured to face the internal volume 10, and a second, opposite face 412.

[0034] Generally, the at least one deformable tab 33 is configured to be disposed in the at least one opening 43 of the cover 4 and to be deformed between an insertion position, visible in [Fig. 6], and a position of attachment of the cover 4 relative to the base 3, visible in [Fig. 7]. In the insertion position, said tab 33 extends along the first direction 100, in continuity with the at least one side wall 32 and transversely to the main flank 41 so as to be able to be inserted into the at least one opening 43, through the main flank 41 of the cover 4. The at least one tab 33 then protrudes from the side wall 32 on which it is mounted.In the secured position, at least one tab 33 is folded down so as to extend transversely to the side wall 32 supporting it, for example parallel or substantially parallel to the main side 4L. In such a position, the cover 4 is interposed between at least a part of the tab 33 and the internal volume 10 along the first direction 100. Optionally, when at least . A tab 33 is arranged in a locking position; it extends at least partially into contact with one of the faces of the cover 4 or at the level of one of the faces of the cover 4, in particular the second face 412 of the main flank 41 of the cover 4.

[0035] In particular, the at least one tab 33 is moved between the insertion position and the locking position, or vice versa, by bending, either automatically by means of a machine or manually, by human intervention. A bearing force is then exerted on at least a part of the at least one tab 33. In particular, the cover 4, as indicated above, is designed to withstand such a bearing force applied to the at least one tab 33 and is designed so as not to be deformed by any force that may be exerted by said tab 33 on the cover 4 when the latter is arranged in a locking position.

[0036] According to one embodiment, at least one tab 33 is folded into the locking position so that a free end 34 of said tab 33 extends towards a central area of ​​the housing 2, i.e. towards an area furthest from the plurality of side walls 32. In this way, only one folding of at least one tab 33 is required.

[0037] According to an alternative not shown, at least one tab 33 is folded into the locking position so that its free end 34 extends towards one of the side walls 32 of the base 3. A first fold is then made so that an intermediate portion of at least one tab 33 extends into contact with the main side 41 of the cover 4, in particular parallel to it. A second fold is then made to move the free end 34 of at least one tab 33 so that it extends transversely to the intermediate portion, for example parallel to one of the side walls 32 of the base 3. At least one tab 33 is then folded into a U-shaped or substantially U-shaped form. Such a more complex fold can help optimize the stability of the base 3 relative to the cover 4 along at least one direction.

[0038] Optionally, as illustrated in Figures 1 to 3, the housing 2 includes a plurality of fastening devices 5 for the cover 4 on the base 3 such that the housing 2 includes a plurality of tabs 33 and openings 43, each tab 33 being configured to be inserted, as described above, into one of the openings 43. The following description is made with reference to a tab 33 and an opening 43; however, it is understood that the various features relating to said tab 33 or said opening 43 may extend to all or part of the plurality of tabs 33 and the plurality of openings 43.

[0039] Preferably, for the purposes of ease of manufacture and reduction of manufacturing costs, the leg 33 and the side wall supporting it are made of material.

[0040] For example, leg 33 has a polygonal shape. Preferably, leg 33 has an elongated, straight or substantially straight shape, by For example, a rectangular or square tab shape. In particular, the tab 33 has a first dimension, along the first direction 100, greater than or equal to 2 cm when said tab 33 is in the insertion position. Specifically, the first dimension 100 of at least one tab 33 is adapted according to the dimensions of the cover 4 and the mass of the battery module 1. The first dimension here corresponds to a length of the tab 33. Alternatively or additionally, the tab 33 has a dimension, along the third direction 300, greater than or equal to 1 cm, or even 2 cm. The second dimension here corresponds to a width of the tab 33 in the illustrated example. Optionally, the tab 33 has a third dimension, corresponding to a thickness, defined along the second direction 200, between 1 mm and 10 mm, or even between 2 mm and 8 mm, or between 3 mm and 6 mm.As mentioned above, the dimensions of pin 33 are adapted according to the dimensions and mass of the battery module 1 in question.

[0041] Optionally but preferably, the free end 34 of the leg 33 includes at least one chamfer 35. Such a chamfer 35 is intended to facilitate the insertion of the leg 33 into the opening 43.

[0042] The opening 43 is configured to allow the passage of the tab 33 that it receives. In particular, the opening 43 is configured to allow the passage of a profile of the tab 33 that it receives, such a profile being defined in a plane orthogonal to the first direction 100. For example, the opening 43 has a shape complementary to at least a portion of the tab 33 that it is configured to receive. In particular, the opening 43 is complementary in shape to the profile of the tab 33 defined in the plane orthogonal to the first direction 100. For example, without limitation, the opening 43 has the shape of a through slot, rectangular or substantially rectangular.

[0043] Optionally, the fastening device 5 includes at least one recess 44 configured to receive all or part of at least one tab 33 when the latter extends into the locked position. The recess 44 is contained within the cover 4, in particular within the main side 41, and is located at the level of at least one opening 43. In particular, the recess 44 opens onto the opening 43.

[0044] For example, the recess 44 can be obtained by cutting or removing material from the thickness of the main side 4L

[0045] Preferably, a length of the recess 44, defined along the second direction 200, is strictly greater than a length of the extreme portion along this same direction so as to allow the positioning, manually or automatically, of the tab 33 in the locking position but also to allow simple gripping of said tab 33 in the event of disassembly of the battery module 1.

[0046] Preferably, the recess 44 is shaped and dimensioned so that, when the tab 33 is in the locking position, it is at least partially continuous with the cover 4, particularly with the second face 412 of the cover 4. In other words, at least a portion of the tab 33 then lies in a plane common to the second face 412 of the main side 41. Such a principle advantageously limits the bulk generated by the tab 33 along the first direction 100. At least one extreme portion 45 of the tab 33, including its free end 34 and corresponding to the folded portion of said tab 33 in the locking position, then extends parallel or substantially parallel to the main side 41 of the cover 4.

[0047] According to yet another alternative, a depth of the recess 44, defined along the first direction 100, is strictly greater than a thickness of the extreme part 45 of the leg 33 so as to be able to receive the whole of the extreme part 45, folded down, of said leg 33, when the latter is in the position of being joined.

[0048] Optionally, the fastening device 5 includes at least one stop member 46, disposed in the cover 4 and extending at least one opening 43. The stop member 46 is configured to act as a stop for the tab 33 extending through the opening 43 along at least one direction when the tab extends into the locked position. In this case, the stop member 46 acts as a stop for the tab 33 along one direction of the first direction 100 when the tab extends into the locked position. The stop member 46 is also capable of acting as a stop for the tab 33 along the second direction 200.

[0049] According to an example of an embodiment, not shown, the stop member 46 is formed by a part of the second face 412 of the main side 41 of the cover 4. The tab 33 is then folded down into the locking position so as to extend into contact with said face.

[0050] According to a preferred embodiment, shown in Figures 4 to 7, the stop member 46 is formed by a bottom of the recess 44 as described above. The tab 33, when positioned in the locking position, then extends into the recess 44, in contact or substantially in contact with the bottom of said recess 44. The bottom of the recess 44 then acts as a stop for the end portion 45 of the tab 33 along one direction of the first direction 100. Also, the bottom of the recess 44 acts as a stop for the tab 33 along the second direction 200.

[0051] When the fastening device 5 comprises a plurality of tabs 33 and openings 43, as described above, each tab 33 is configured to be arranged in one of the openings 43. The plurality of tabs 33 can then be distributed within base 3 according to different alternative embodiments which can advantageously be combined with each other, the folding of said legs 33 not presenting any specific constraints on the position or orientation thereof.

[0052] For example, the legs 33 can be divided into a plurality of subsets arranged such that at least two subsets of legs 33 are connected to two distinct, opposing side walls 32, as illustrated in the figures. Such an arrangement advantageously minimizes the number of legs 33 required while optimizing the attachment of the cover 4 to the base 3.

[0053] Optionally and preferably, at least two legs 33 are arranged at the level of the same lateral wall 32. In other words, a considered subset then also includes a plurality of legs 33. For example, said legs 33 are regularly spaced within the lateral wall 32 considered.

[0054] Optionally, additionally or alternatively, at least two subsets of legs 33 can be connected to two separate adjacent side walls 32.

[0055] It is understood that the position of the openings 43 within the cover 4, in particular the main side 41, is then adapted accordingly and that the preceding description applies mutatis mutandis to all or part of the tabs 33 and / or openings 43.

[0056] The invention further extends to a method for assembling the battery module 1 according to the invention. Generally, such a method comprises a step of positioning at least one electrochemical cell 11 on the main wall 31 of the base 3 of the housing 2. The at least one electrochemical cell 11 is then arranged in the internal volume 10 of the housing 2. A similar principle applies when the battery module 1 comprises a plurality of electrochemical cells 11.

[0057] The method then comprises positioning the cover 4 on the housing 2 so as to close the housing 2, which includes at least one electrochemical cell 11. At least one tab 33 is then arranged in the insertion position, i.e., it extends along the first direction 100 as seen in [Fig. 6], in continuity with the side wall 32 carrying it, so that when the cover 4 is placed on the base 3, at least one tab 33 extends through at least one opening 43 in the cover 4. It is understood that, when the fastening device 5 of the housing 2 comprises a plurality of tabs 33 and openings 43 as described above, the various tabs 33 are arranged in the insertion position and extend along the first direction 100 so that each can be inserted into one of the openings 43 in the cover 4.

[0058] Once the cover 4 is positioned, that is, once it is in contact with the base 3 and at least one tab 33 is positioned through at least one opening 43, the method includes a step of securing the cover 4 to the base 3. Such This step is performed by moving the outermost part 45 of at least one tab 33 from the insertion position to the locking position, i.e., by deforming at least one tab 33, in particular by folding. Such folding can be carried out according to the different orientation alternatives described above. This type of folding can also be carried out so that at least one tab 33 extends into the recess 44 and / or against the stop member 46 described above. Finally, the folding can advantageously be carried out automatically, by a machine, or manually.

[0059] To disassemble the battery module 1 according to the invention, for example in order to replace at least one electrochemical cell 11 or one of the electrochemical cells, the reverse process is carried out.

[0060] The present invention thus provides a housing for a battery module that reduces the number of reference parts required for assembling the housing. The manufacturing cost of a battery module incorporating such a housing is therefore advantageously reduced. The assembly and disassembly of the module are also simplified.

[0061] The present invention cannot, however, be limited to the means and configurations described and illustrated herein and it also extends to any equivalent means or configuration and to any technically operative combination of such means insofar as they ultimately fulfill the functionalities described and illustrated in this document.

Claims

Demands

1. Housing (2) for a motor vehicle battery module (1) comprising a base (3) open on one side having a plurality of walls, including at least one main wall (31) and side walls (32) connected to the main wall (31), and a cover (4), comprising at least one main flank (41) configured to be mounted on the base (3) so as to close the housing (2), characterized in that the housing (2) further comprises at least one fastening device (5) comprising: - at least one opening (43), disposed in the main flank (41);- at least one deformable leg (33), connected to at least one of the side walls (32), configured to be disposed in at least one opening (43) and to be deformed between an insertion position, in which said leg (33) extends along a first direction (100), in continuity with at least one side wall (32) and transverse to the main side (41), and a position of securing the cover (4) relative to the base (3) in which said leg (33) extends transversely to said wall.;

2. Housing (2) according to the preceding claim, wherein: - the base (3) is made of a metallic material, such as sheet steel and / or aluminum; and / or - the cover (4) is made of a plastic material, such as a filled or unfilled polymer, and / or of a metallic material, such as sheet steel and / or aluminum.

3. Housing (2) according to any one of the preceding claims, wherein at least one leg (33) and at least one of the side walls (32) of the base (3) are made of material.

4. Housing (2) according to any one of the preceding claims, wherein at least one fastening device (5) comprises at least one stop member (46), disposed in the cover (4) and extending at the level of at least one opening (43), said stop member (46) being configured to form a stop for at least one tab (33) along at least one direction when the latter extends into the locking position.

5. Housing (2) according to any one of the preceding claims, wherein at least one fastening device (5) includes at least one recess (44), disposed at the level of at least one opening (43), configured to receive at least one tab (33) when it extends into the locking position.

6. Housing (2) according to any one of the preceding claims, wherein: - at least one tab (33) has a dimension, along the first direction (100) when said tab (33) is in the insertion position, greater than or equal to 2 cm; and / or - at least one tab (33) has a dimension, along a second direction orthogonal to the first direction (100), greater than or equal to 1 cm, or even 2 cm.

7. Housing (2) according to any one of the preceding claims, comprising a plurality of fastening devices (5) such that the housing comprises a plurality of tabs (33) and openings (43), each tab (33) being configured to be disposed in one of the openings (43), the plurality of tabs (33) being distributed into a plurality of subsets arranged such that: - at least two subsets of tabs (33) are connected to two separate, opposite side walls (32); and / or - at least two subsets of tabs (33) are connected to two separate, adjacent side walls (32); and / or - at least two tabs (33) are disposed at the same side wall (32).

8. Battery module (1) comprising a housing (2) according to any one of the preceding claims, delimiting an internal volume (10), and at least one electrochemical cell (11) disposed in said volume.

9. Electric or hybrid motor vehicle comprising a housing (2) according to any one of claims 1 to 7 and / or at least one battery module (1) according to claim 8.

10. A method for assembling a battery module (1) according to claim 8 comprising: - a step of positioning at least one electrochemical cell on the main wall (31) of the base (3) of the housing (2); - a step of positioning the cover (4) on the housing (2) so as to dispose of at least one electrochemical cell in the internal volume and so as to close the housing (2), at least one tab (33) being disposed in the insertion position and extending through at least one opening (43) of the cover (4); - a step of securing the cover (4) to the base (3) by moving at least one tab (33) from the insertion position to the securing position.

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